PPM Users Manual Signature Software

PPM User Manual 11/18/02 Software Versions: 0.0.
27
Promess Montage- und Prfsysteme GmbH Berlin

1

PPM Users Manual
Signature Software
01-12-00

PPM User Manual 11/18/02 Software Versions: 0.0.15

2
Contents
1. Introduction 2
2. Parameters 3
2.1 Overload Limit.............................................................................................4
2.2 Relative Upper Limit ...................................................................................4
2.3 Relative Lower Limit ...................................................................................4
2.4 Absolute Upper Limit ..................................................................................5
2.5 Absolute Lower Limit..................................................................................5
2.6 Start of Window...........................................................................................5
2.7 End of Window............................................................................................5
2.8 Slice Width...................................................................................................5
2.9 Slice Tolerance.............................................................................................6
2.10 Force Limit.................................................................................................6
2.11 Peak Force Monitoring ..............................................................................7
Peak Upper Limit ...................................................................................7
Peak Lower Limit ..................................................................................7
2.12 Global Peak Force Monitoring...................................................................7
Global Peak Upper Limit .......................................................................7
Global Peak Lower limit ........................................................................7
2.13 Touch Point Limit ......................................................................................8
2.14 Touch Point Tolerance...............................................................................8
2.15 Full Depth Tolerance .................................................................................9
3. Teaching the System 10
3.1 Teaching The Signature Curve ..................................................................11
3.2 Adjusting Parameters.................................................................................12
3.3 Window Limits Screen ..............................................................................13
3.4 Global Limits Screen .................................................................................15
3.5 Zoom Window Screen ...............................................................................16
3.6 Example Teach-In Press Application.........................................................17
4. Automatic Mode 18
4.1 The Fault List Screen.................................................................................19
4.2 Information Screens...................................................................................20
4.2.1 Manufacturing Summary Screen ................................................20
4.2.2 Part Data Screen..........................................................................21
4.2.3 Taught Data Screen.....................................................................21
4.2.4 Data Lists Screen ........................................................................22
5.0 The Service Menu 24
5.1 Diagnostics.................................................................................................24
5.1.1 Sensor Signals.............................................................................25
5.1.2 Input Check.................................................................................26


3
5.1.3 Relay Output Check....................................................................27
5.2 Calibration..................................................................................................28
5.2.1 Calibrate Force............................................................................29
5.2.2 Calibrate Position........................................................................31
5.2.3 Reset Force Factor ......................................................................33
5.2.4 Reset Position Factor ..................................................................33
5.2.5 Edit Force Factor.........................................................................34
5.2.6 Edit Position Factor.....................................................................35
5.3 Setup Screen...............................................................................................36
5.3.1 Changing Password.....................................................................37
5.3.2 Changing Date and Time ............................................................38
5.3.3 Serial Baud Rate .........................................................................38
5.3.4 Changing Language ....................................................................39
6. RS232 Serial Communication 40
6.1 Communication Settings............................................................................40
6.2 Signal Description......................................................................................40
6.3 Command Format ......................................................................................41
Command: TPT<CR>.........................................................................42
Command: TPL<CR>.........................................................................42
Command: TPS<CR>.........................................................................42
Command: TPA<CR> ........................................................................42
Command: FDA<CR>........................................................................43
Command: FDT<CR> ........................................................................43
Command: FDL<CR> ........................................................................43
Command: FDS<CR>.........................................................................43
Command: PFW<CR>........................................................................44
Command: PFG<CR>.........................................................................44
Command: CWA<CR>.......................................................................45
Command: CWT<CR>.......................................................................45
Command: CWL<CR>.......................................................................45
Command: CWS<CR> .......................................................................46


2
1. Introduction
The Promess Assembly Monitoring System is designed to monitor, in-process,
the quality of a press-fit, staking or crimping operation or any other process
requiring signature monitoring. The system consists of a microprocessor based
electronic unit which monitors the signals from force and position sensors
mounted on the machine. Information obtained from these sensors is used to
create a force/position signature curve, which is compared to an "ideal" taught
profile. If the force exceeds preset limits (either upper or lower), or if the part is
not pressed to the correct depth, a fault is indicated.
The assembly profile is monitored within an adjustable window, which allows the
user to define the critical portion of the assembly operation for precise in-process
quality information.
Individual stations can also be linked together to a single monitoring PC using a
daisy-chain method. While each station is responsible for monitoring its own
operations in real time, the host PC collects all resulting data from each station
for viewing, editing and analysis. The data acquisition software is Windows-
based and can be used in a single or multi-station configuration.


3
2. Parameters
The Promess Assembly Monitoring System has multiple parameters that can be
used during the assembly monitoring process. Note: the Overload limit, Force
Limit, Absolute Limits, the Peak limits are disabled as a default setting in the Limit
Enable screen. If any of and these limits are to be used, they must be enabled in
the Limit Enable screen in the hidden setup menu (see technical manual).

Overload Limit Slice Tolerance
Relative Upper Limit Force Limit
Relative Lower Limit Peak Upper Limit
Absolute Upper Limit Peak Lower Limit
Absolute Upper Limit Global Peak Upper Limit
Start of Window Global Peak Lower Limit
End of Window Touch Point Limit
Slice Width Full Depth Limit

Force
Position
Overload
Limit
Monitoring
Window
- +
T
o
u
c
h

P
o
i
n
t

T
o
l
e
r
a
n
c
e
Touch
Point Limit
S
t
a
r
t

o
f
W
i
n
d
o
w
E
n
d

o
f
W
i
n
d
o
w
- +
F
u
l
l

D
e
p
t
h

T
o
l
e
r
a
n
c
e
Upper
Limit
Lower
Limit


4
2.1 Overload Limit
The over load limit is a real time limit and is active when the monitored input is
high. When the force exceeds the overload limit, an overload fault output is
triggered.

Force
Position
Overload
Limit

2.2 Relative Upper Limit
The relative upper limit is monitored from the Start of Window to the End of
Window. The relative upper limit is calculated by taking the relative upper limit
setting and adding it to the taught-in force profile. If the force at any position
during the monitoring window exceeds the upper limit, a force fault will occur.
2.3 Relative Lower Limit
The relative lower limit is monitored from the Start of Window to the End of
Window. The relative lower limit is calculated by taking the relative lower limit
and subtracting it from the taught-in force profile. If the force at any time during
the monitoring window drops below the lower limit, a force fault will occur.
Position
Relative
Lower Limit
Relative
Upper Limit
Monitoring Window


5
2.4 Absolute Upper Limit
The absolute upper limit is monitored from the Start of Window to the End of
Window. If the force at any position during the monitoring window exceeds the
upper limit, a force fault will occur.
2.5 Absolute Lower Limit
The absolute upper limit is monitored from the Start of Window to the End of
Window. If the force at any position during the monitoring window falls below the
lower limit, a force fault will occur.

2.6 Start of Window
The position where monitoring will start. If the touch point limit is set to 00%, then
the start of window is an absolute setting of the position axis. If the touch point is
used, the start of window will be relative to the touch point.
2.7 End of Window
The position where monitoring will end. If the touch point limit is set to 00%, then
the end of window is an absolute setting of the position axis. If the touch point is
used, the end of window will be relative to the touch point.
2.8 Slice Width
This specifies how many slices the monitoring window will be separated into for
analysis. The monitoring window is sliced into position dependent slices, and
within each slice, an average force is computed. Each slice has an associated
upper and lower limit, which are used when certifying the part. The Number of
Slices can only be changed in the Teach mode.
Force
Position
Absolute
Upper Limit
Absolute
Lower Limit
Monitoring
Window


6
2.9 Slice Tolerance
This parameter shifts each window increment to the right and left and takes the
highest and lowest value to establish the limits. This is used to compensate for
variations in position causing the force curve to shift. This parameter is set in the
setup menu.
Force
Position
Relative
Lower Limit
Relative
Upper Limit
Monitoring Window
Start of
Window
End of
Window

2.10 Force Limit
The Force limit is a real time limit that can be used to ensure a certain force is
reached or to control the ram to press to a force. The monitoring of the force limit
is active when the monitored input is high.

Force
Position
Force
Limit


7

2.11 Peak Force Monitoring
The Peak Force value that is displayed is the highest force the unit recorded with
the monitoring window during the process.
Peak Upper Limit
The Peak Upper limit is a straight line limit. If the peak force measured exceeds
the Peak Upper limit then a Peak limit fault will occur at the end of the cycle.
Peak Lower Limit
The Peak Lower limit is a straight line limit. If the peak force measured is lower
then the Peak Lower limit then a Peak limit fault will occur at the end of the cycle.
2.12 Global Peak Force Monitoring
The Global Peak Force value is the highest force that the unit recorded that was
inside or outside the monitoring limit.
Global Peak Upper Limit
The Peak Upper limit is a straight line limit. If the peak force measured exceeds
the Peak Upper limit then a Peak limit fault will occur at the end of the cycle.
Global Peak Lower limit
The Peak Lower limit is a straight line limit. If the peak force measured is lower
then the Peak Lower limit then a Peak limit fault will occur at the end of the cycle.


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2.13 Touch Point Limit
The initial contact of the parts is recognized by this limit. The start of window and
end of window are relative to the touch point.
Force
Position
Monitoring
Window
Touch Point
Limit
Touch Point
Tolerance

2.14 Touch Point Tolerance
Based upon the taught-in touch point position, the user can set a plus/minus
tolerance that the initial part contact (Touch Point) must be within. When the
Assembly Monitoring System is taught, the system stores the Touch Point
Position. The Touch point tolerance set in the parameter screen and the value
entered is added and subtracted from the taught Touch Point position to create
the tolerance.

Example: Taught in Touch Point Position is 13.50mm
Touch Point Tolerance is 2.00mm
Then the lower limit is 11.50mm and the upper limit is 15.50mm.
So if the Touch Point position is less than 11.50mm or greater than
15.50mm then a fault will be sent.
00.00 11.50 13.50 15.50 25.00
Position
Lower Tolerance Taught Upper Tolerance


9
2.15 Full Depth Tolerance
Based upon the taught-in full depth position, the user can set a plus/minus
tolerance that the final press position must be within.
When the Assembly Monitoring System is taught, the system stores the Full
Depth Position (The furthest value that the position transducer traveled). There
are two full depth tolerances that can be set in the monitoring system:

Full Depth + Tolerance (Full Depth +)
Full Depth - Tolerance (Full Depth -)
The Full Depth + Tolerance is added to the taught-in full depth value to set the
upper limit and the Full Depth - Tolerance is subtracted from the full depth value
to set the lower limit. The full depth measurement can be either an absolute
measurement or a relative measurement when touch point is used. Note: if the
full depth measurement is not going to be used, then set the limits large enough
to give no faults.

Example Taught Full Depth is 15.20 mm
Full Depth + Tolerance +2.00
Full Depth - Tolerance -1.20
So the full depth position must fall within 14.00 to 17.20 mm tolerance otherwise
the part will not pass the full depth measurement.

00.00 14.00 15.20 17.20 25.00
Position
Lower Tolerance Taught
Upper Tolerance


10
3. Teaching the System
The TEACH function is used to teach the Monitoring System the force versus
position signature. The unit will switch to the automatic mode once the teach
count has been reached. The icon in the upper right corner will display a "T" for
teach (versus "A" for automatic). The Overload Limit, Force Limit and the Peak
Force Limits are the only limits monitored in the teach mode. If one of these
faults occur in the teach mode, the system will stay in the teach mode until a part
is taught-in with no faults.
To access the Teach Mode from the Main Menu, press the button labeled
TEACH. To access the Teach Mode from the Automatic Mode, press the button
labeled MAIN to access the Main Menu and then press the button labeled
TEACH to access the Teach Mode. The software will ask if you wish to reteach
the part. Press Yes to go into Teach or No to exit back to the Main Menu. The
system can store 8 different force/position signature curves and parameters,
however, when the system is put into Teach, only the part number currently
active will be taught. With option memory, up to 64 parts can be taught and
stored. The part number is displayed in the Main Menu in the lower right hand
corner. The part number is sent using the binary inputs via the interface cable.

PROMESS
INCORPORATED
Promess Panel Meter
Version 0.0.9
May 11, 1999
Station: 99 Program: 1
Teach
Auto-
matic
Serv-
ice


11
Main
Limits
Setup
Informa-
tion
0.00
Force
Depth
T
mm 25.00
1000
750
500
250
0
0 lbs
0 mm Prog: 1
lbs

3.1 Teaching The Signature Curve
When in the teach mode, the monitoring system collects and stores both the
force and position data during working stroke of the position transducer. In the
hidden setup menu under Axis Value Setup, the position range that you want
data collected over can be adjusted if necessary. This would only need to be
done if you had a long stroke portion transducer but are only using a small
amount of travel during the assembly operation.
To teach a signature into the system, take parts that are close to the mean and
press them together. The two parts that are going to be assembled do not have
to be exactly on the mean. The upper and lower limits are separate limits, so if
the taught-in signature is above the mean, then the upper limit will be set to a
lower value than if a mean part was taught in.
The system will indicate when it is in the teach mode by displaying a T in the
upper right hand corner of the screen. An A is used to indicate the system is in
the automatic mode. After on part is taught, the system will automatically switch
to the automatic mode. In teach the only limits that are monitored are the
Overload Limit and the Peak Force Limits.
In either the teach mode or the automatic mode any of the monitoring parameters
can be changed without having to reteach the system.
The screen in the teach mode.


12
* Global Limits *
Exit
Full Depth +
Full Depth -
2.50 mm
Edit
Window
Limits
Zoom
Setup
2.50 mm
Main
Limits
Setup
Informa-
tion
0.00
Force
Depth
T
mm 25.00
1000
750
500
250
0
0 lbs
0 mm Prog: 1
lbs

3.2 Adjusting Parameters
There are three different screens where various parameter can be adjusted,
Window Limits, Global Limits and Zoom Window.
Window Limits: In this screen, limits that are only for the Monitoring
Window can be adjusted.
Global Limits: In this screen, limits that are monitored inside and
outside the monitoring window can be adjusted.
Zoom Window: This is the screen where the zoom window is set.

* Window Limits *
Exit
Rel. Upper L.
Start Window
End Window
Slice Width
10 lbs
0.20mm
Edit
Global
Limits
Zoom
Setup
25.00mm
0.00mm
10 lbs Rel. Lower L.


13
* Zoom Window *
Exit
X Axis
Y Axis
0.00 to 25.00 mm
0 to 100 lbs
Edit
Global
Setup
Window
Setup

3.3 Window Limits Screen
In the Program Limits Screen the following parameters can be changed: The
Start of Window, End of Window and the Slice Width can be set. The Start of
Window and End of Window define where the system monitors the relative upper
and relative lower signature limits. The limits can be adjusted without having to
reteach the system. The following parameters can be changed. Note: The Peak
Upper Limit, Peak Lower Limit, Absolute Upper Limit and Absolute Lower Limit
will not appear if disabled in the hidden setup.
Relative Upper Limit End of Window Peak Lower Limit
Relative Lower Limit Slice Width Absolute Upper Limit
Start of Window Peak Upper Limit Absolute Lower Limit

* Window Limits *
Exit
Rel. Upper L.
Start Window
End Window
Slice Width
10 lbs
0.20mm
Edit
Global
Limits
Zoom
Setup
25.00mm
0.00mm


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* Window Limits *
Exit
Start Window
End Window
Slice Width
5.00 mm
20.00 mm
0.60 mm
- +
* Window Limits *
Exit
Rel. Upper L.
Start Window
End Window
Slice Width
10 lbs
0.20mm
Edit
Global
Limits
Zoom
Setup
25.00mm
0.00mm
Abs. Upper L.
Abs. Lower L.
Peak Upper L.
Peak Lower L.
To change a parameter setting, press the Edit button to access the editing mode.
Button Function
Moves the edit box up or
down.
Clear Clears the current setting.
Exit Returns to the previous
screen.

Changing a Parameter
Move the edit box up or down to the parameter to be changed. Press the Clear
button and type in the parameter setting. Pressing the Enter button or the Exit
button will save the value. Press Exit to exit out of the edit mode and then press
Exit to exit back to the graph screen.

When you scroll down to Slice Width, the functions of the buttons change to up
arrow, +, - and Exit, see screen below. Press Exit to exit out of the edit mode
and the press Exit to exit back to the graph screen.

Button Function
Moves the edit box up.
+ Increments the slice width.
- Decrements the slice
width.
Exit Returns the software to
previous screen.


15
3.4 Global Limits Screen

In the Monitoring Window screen, the following parameters can be changed.
Overload limit, full depth tolerance, Global peak force limits and the force limit.
Note: The Overload limit , Global peak force limits, force limit, and the touch point
will not appear if disabled in the hidden setup screen.
* Global Limits *
Exit
Overload L.
Full Depth +
Full Depth -
G. Peak U. L.
G. Peak L. L.
100 lbs
2.50 mm
0 lbs.
Edit
Window
Limits
Zoom
Setup
Force Limit 0 lbs.
0 lbs.
2.50 mm
Touch Point +
Touch Point -
2.50 mm
2.50 mm

To change a parameter, press the Edit button to access the edition mode.

Button Function
Moves the edit box up
or down.
Clear Clears the current
setting.
screen.

Move the edit box up or down to the parameter to be changed. Press the Clear
button and type in the parameter setting. Press the Enter button or the Exit
button will save the value. Press Exit to exit out of the edit mode and then press
Exit to exit back to the graph screen.
* Global Limits *
Exit
Overload L.
Full Depth +
Full Depth -
G. Peak U. L.
G. Peak L. L.
100 lbs
2.50 mm
0 lbs.
Force Limit 0 lbs.
0 lbs.
2.50 mm
Clear
Touch Point +
Touch Point -
2.50 mm
2.50 mm


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* Zoom Window *
Exit
X Axis
Y Axis
0.00 to 25.00 mm
0 to 100 lbs
Clear
3.5 Zoom Window Screen
In the Zoom Window, the force and position settings for the zooming function can
be set. When in the graph screen, pressing the +/- button will toggle the screen
from the full graph to the zoom window.
* Zoom Window *
Exit
X Axis
Y Axis
0.00 to 25.00 mm
0 to 100 lbs
Edit
Global
Setup
Window
Setup

The following screen appears when entering the Zoom Setup.

Button Function
Moves the edit box up or
down.
Clear Clears the current setting.
screen.

To change a parameter, move the edit box using the up and down arrow keys.
Press the Clear button and then type in the new value and press Enter or Exit to
accept the value. To exit out of the Zoom Window screen press the Exit button.


17
3.6 Example Teach-In Press Application
Application: pressing a bearing into a housing to a shoulder.
The bearing height is 10mm and the housing depth is 10mm. The position
transducer has a 25mm stroke length and touch point is not going to be used.
First put the Assembly Monitoring System into the Teach Mode and set the Start
of Window to 00.00 and the End of Window to 25.00 (full range) in the parameter
screen, the other parameters can be left at the default values. Run a cycle,
teaching in the force/position curve and the full depth position. Note the full depth
value show in the upper left hand corner of the screen and ignore the force
position curve. For our example, the full depth value is 20.50. To set up the
monitoring window to only look at the critical part of the press-fit, subtract 1mm
from the full depth and use this as the End of Window value (19.50). Then
subtract 8mm from the full depth value and use this as the Start of Window value
(12.50). The critical part of the press-fit is now defined and the force/position
curve will be shown on the screen. If necessary, adjust the full depth tolerance.
Note: this is just an example and each press-fit application will have a different
set of parameters. If you have any questions about setting the window, call
Promess at 810-229-9334 for assistance.
10
Ram
Bearing
10
Housing

Force
Position
Monitoring
Window
Force
Position
Monitoring
Window


18
4. Automatic Mode
In the Automatic Mode, the monitoring of the press fit operation occurs. The
upper and lower limits, the full depth position, the touch point position are
monitored in the automatic mode (the Overload limit, the Force limit and the Peak
Force limits are also monitored if enabled in the hidden setup menu. The
force/position curve is displayed on the LCD screen and is updated after each
cycle. The lighter lines are the upper and lower limits and the dark solid line is
the actual press force curve. An "A" is displayed in the upper right hand corner to
indicate the system is in the Automatic mode. The Full depth position is also
displayed in the upper left hand corner of the screen. Using the menu buttons,
there are four options in the automatic mode

Main
Limits
Setup
Informa-
tion
0.00
Force
Depth
A
mm 25.00
1000
750
500
250
0
980 lbs
21.45 mm
PASS
Prog: 1
lbs

Button Function
Limits Setup Brings up the Window limits screen where the parameters
can be changed or the Global Limits or the Zoom Setup can
also be accessed.

Information Brings up the information screens.

Main Returns the software to the Main Menu.


19
4.1 The Fault List Screen
The Fault List screen lists any faults that occur during the last cycle. This screen
is updated after each cycle and the errors displayed are for the last part ran. To
access the Fault List screen, press the button labeled Information. To exit back
to the graph screen, press the button labeled EXIT. The system still monitors
when in the Fault List screen.

* Fault List *
Exit
No Faults
Part
Data
Man.
Sum.
Data
Lists

Note: If the force limit is enabled, then the following message will be displayed
if the force limit is not reached, Force Limit Not Reached. This does not trigger
the Fail output.


20
* Manufacturing Summary *
Exit
Reset
Counts
Total Parts:
0
0
Good Parts:
Bad Parts:
Rel. Upper L. :
0
0
0
Fault
List
Rel. Lower L. :
Full Depth + :
Full Depth - :
0
0
4.2 Information Screens
In the Information Screens, the faults and part data can be viewed. The Fault
Lists screen will be displayed.
* Fault List *
Exit
No Faults
Part
Data
Man.
Sum.
Data
Lists

4.2.1 Manufacturing Summary Screen
Pressing the Man. Sum. Button will access the Manufacturing Summary Screen.
The Manufacturing Summary screen displays the Total number of parts, Good
Parts, Bad Parts, Relative Upper limit faults, Relative Lower limit faults and the
Full Depth faults.

Button Function
Fault List Returns software to
Fault List screen
Moves the edit box
down.
Reset Counts Clears the current
setting.
Exit Returns to the
previous screen.

If the Touch point, the Overload limit, the Force limit Absolute or the Peak force
limits are enabled in the hidden setup screen, then they will appear in the
Manufacturing summary screen. There is a separate manufacturing screen for
every part number.


21
4.2.2 Part Data Screen
Pressing the Part Data button will show the data for the last part ran.
* Part Data *
Exit
Taught
Data
Full Depth
G. Peak Force
W. Peak Force
19.30 mm
9 lbs.
9 lbs.
Fault
List
Data
Lists
Touch Point
W. Peak Slice
W. Last Slice
9 lbs.
9 lbs.
13.14 mm

4.2.3 Taught Data Screen
Pressing the Taught Data button will show the data for the taught in part.
* Taught Data *
Exit
Part
Data
Full Depth 19.30 mm
Fault
List
Data
Lists
Touch Point 13.14 mm
G. Peak Force
W. Peak Force
W. Peak Slice
W. Last Slice
35 lbs
35 lbs
35 lbs
35 lbs


22
4.2.4 Data Lists Screen

Pressing the Data Lists button will show the Data for the last eight (8) parts. The
most recent part will be at the top of the list.
* W. Peak Force List *
Exit
W. Last
Slice
Full
Depth
Prog.
PASS
Status Peak Force
35 lbs
34 lbs
37 lbs
35 lbs
35 lbs
34 lbs
35 lbs
38 lbs
1
1
1
1
1
1
1
1
PASS
FAIL
PASS
PASS
PASS
PASS
FAIL

The following screen appears when pushing the Full Depth button.
* Full Depth List *
Exit
W. Last
Slice
Full
Depth
Prog.
PASS
Status Full Depth
19.64 mm
19.64 mm
19.64 mm
18.02 mm
19.64 mm
19.64 mm
19.64 mm
19.64 mm
1
1
1
1
1
1
1
1
PASS
PASS
FAIL
PASS
PASS
PASS
PASS


23
The following screen appears when pushing the W Last Slice button.
* W. Last Slice List *
Exit
Full
Depth
W. Peak
Force
Prog.
PASS
Status Last Slice
35 lbs
34 lbs
34 lbs
34 lbs
37 lbs
34 lbs
34 lbs
34 lbs
1
1
1
1
1
1
1
1
PASS
PASS
PASS
FAIL
PASS
PASS
PASS

To exit out of the Data Lists press Exit button.


24
Service Menu
Main
Diag-
nostics
Setup Calibrate
* Diagnostics Menu *
Exit
Sensor Signals
Inputs
Outputs
Analog
Quadrature Input
Serial Port
Memory Check
Arcnet Check
Select
5.0 The Service Menu
From the Control Menu the Diagnostics, Setup, Calibration or Main Menu can be
accessed.
Button Function
DIAGNOSTICS Selects the
Diagnostics
Menu.
CALIBRATE Selects the
Calibrate Menu.
SETUP Selects the Setup
Menu.
MAIN Returns the
software to the Main
Menu.

5.1 Diagnostics
From the Diagnostics Menu, the Analog Check, Input Check or the Output Check
can be selected.
Sensor Signal: Displays the force and position in real time.
Inputs: Displays the current states of the inputs.
Outputs: Displays the current states of the outputs.

Button Function
Moves pointer to desired
option.
SEL Selects the option the
arrow is pointing to.
EXIT Returns the software to
the Service Menu.


25
5.1.1 Sensor Signals
The Real Time screen will display the force and position values numerically and
in a bar display. This screen can be used when calibrating the system or to verify
that the force and position transducers are working properly.

* Sensor Signals *
Exit
(Tare)
Force 0 lbs
Position 0.00 mm
Zero
Tare/
Absol.

Button Function
T/A Toggles between the Tare and Absolute modes. Tare mode uses
the current offset values as the zero value when the ZERO button is
pressed. The Absolute displays the actual analog values from the
transducers. A "T" or an "A" will be displayed in the upper right
hand corner of the screen.
ZERO Pressing the ZERO button when the system is in the Absolute
mode will tare (zero) only the force transducer. When the system is
in the Tare mode and the ZERO button is pushed, then the current
offset values for both the force and position transducers become
the zero points and the readings displayed are relative to the values
when the zero button was pushed.
MAIN Returns the software to the DIAGNOSTICS MENU.

Note: When a Strain Gauge transducer is selected in the Hidden Setup Menu,
then the CAL button will be displayed on the screen. When the CAL button is
pushed, a signal will be sent to the preamplifier to activate the CAL Resistor.


26
5.1.2 Input Check
The Input Check is used to view the current states of the 8 digital inputs: 0 =
OFF, 1 = ON. The Input Check can be used to verify that the Monitoring
System is receiving the outputs from the PLC or output device. Pressing the
MENU button returns the software to the Diagnostics Menu.

* Inputs *
Exit
Inputs:
1 2 3 4 5 6 7 8
0 0 0 0 0 0 0 0

1 = Monitored Input
2 = Reset fault Input
3 = Binary 1 Input
4 = Binary 2 Input
5 = Binary 4 Input
6 = Binary 8 Input
7 = Not Used
8 = Lockout Input


27
* Relay Outputs *
Exit
Relay:
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
Toggle
5.1.3 Relay Output Check
The Relay Output Check is used to view the current states of the outputs. The
screen also permits the toggling of the outputs to verify that the PLC or other
device is recognizing the outputs. The outputs will be reset to their original states
when exiting the output check. Pressing the MENU button will return the
software to the Service screen. The default settings for the relay outputs are
listed below. If the assignment of the relay outputs has been changed, consult
the system drawings for the correct output description.
R1 = Pass (N.O.)
R2 = Failed (N.C.)
R3 = Overload (N.C.)
R4 = Relative Upper Limit Fault (N.C.)
R5 = Relative Lower Limit Fault (N.C.)
R6 = Full Depth Fault (N.C.)
R7 = Ready (N.O.)
R8 = Piezo Sensor Reset: FACTORY SETTING DO NOT CHANGE !!

The signals that are assigned to each relay output can be changed. See Edit
Relay (see technical manual) in the Hidden Setup Menu.

Button Functions
Positions the "cursor box"
on the desired relay output.
Toggle Toggles the state of the
relay.
MENU Returns the software to
the Diagnostics Menu.


28
* Calibration *
Exit
Calibrate Force
Calibrate Position
Reset Force Factor
Reset Position Factor
Edit Force Factor
Edit Position Factor
Select
5.2 Calibration
In calibration, the force transducer can be calibrated using a master load cell and
meter. The position transducer can be calibrated using a gauge block. The force
and position factors can also be reset and adjusted in the calibration screen.
To enter the calibration screen, go to the Service screen and press the
Calibration button. The unit will then prompt you to enter the password. Enter
the password using the numeric keypad. The default password is 123. To
change the password, go to the setup menu.
* Password Protect *
Exit
Enter Password:
123
Then Press "Enter".
Clear

Once the password is entered correctly and the ENTER key is pressed, the
following screen will appear.

Calibrate Force: Allows the force transducer to be calibrated to a
known load.
Calibrate Position: Allows the position transducer to be calibrated to a
known gauge block value.
Reset Force Factor: Resets the software force factor back to the default.
Reset Position Factor: Resets the software position factor back to the default.
Edit Force Factor: Allows the software force factor to be adjusted thru the
faceplate.
Edit Position Factor: Allows the software position factor to be adjusted thru
the faceplate.


29
Calibration complete.
Remove all load
and then press "Enter"
to continue.
5.2.1 Calibrate Force
Using the Calibrate Force function, the force transducer can be calibrated to a
known load. This load can be a master load cell and meter. To Calibrate with a
known load, complete the following steps.
When Calibrate Force is selected the following screen appears. Make sure no
load is being applied to the load cell (ram) and press the Zero button.
Remove all load
then press "Zero".
Zero Cancel

Next apply the known load and enter the load value applied. Then press the
Calibrate button to calibrate to the load.
Apply load and
enter load applied:
Cali-
brate
Exit
100.00 lbs.
Then press "Calibrate"
to calibrate the load.
Clear


30
The analog display will be shown with the force factor calculated.
* Edit Force Factor *
Exit
(Tare)
Force 0 lbs
Factor:
0.003391 lbs/ADC
Zero
Tare/
Absol.
Press "ENTER" to edit.

If no load is detected during this step, a fault will be given.
WARNING !!!
Calibration Failed.
Ok
No load was applied.


31
Calibration complete.
Remove gauge block
and then press "Enter"
to continue.
5.2.2 Calibrate Position
Using the Calibrate Position function the position transducer can be calibrated to
a known position value using a gauge block. To calibrate with a gauge block,
complete the following steps. Note: If a digital position transducer is being used,
there is not need to use the Calibrate position function.
When Calibrate Position is selected the following screen appears. Make sure
the position transducer is zeroed with gauge block installed, and then press the
Zero button.
Move to zero position
then press "Zero".
Zero Cancel

Next insert the gauge block, enter the gauge block value and then press the
Calibrate button. After the unit has finished the calibration, a message will
appear and tell you to remove the gauge block and press the Enter key.
Insert gauge block and
enter length of gauge
Cali-
brate
Exit
25.00 mm
Then press "Calibrate"
to calibrate to
Clear
block:
position.


32
The analog display will be shown with the position factor calculated.
* Edit Position Factor *
Exit
(Tare)
Force 0 mm
Factor:
0.003391 mm/ADC
Zero
Tare/
Absol.

If the position transducer is not moved, then a fault message will be displayed.
WARNING !!!
Calibration Failed.
Ok
No gauge block inserted.


33
5.2.3 Reset Force Factor
The Reset Force Factor is used to reset the force factor back to the default
setting.
Reset force factor
to full range ?
Yes No
* Reset Force Factor *

5.2.4 Reset Position Factor
The Reset Position Factor is used to reset the position factor back to the default
setting.
Reset position factor
to full range ?
Yes No
* Reset Position Factor *


34
5.2.5 Edit Force Factor
In the Edit Force Factor screen the Force Factor can be changed manually. The
following screen will be displayed.
Exit
(Tare)
Force 0 lbs
Factor:
0.003391 lbs/ADC
Zero
Tare/
Absol.

Editing the Force Factor.
Press the Enter button to edit the force factor. The following screen will appear.
Use the numeric keypad to edit the value.
Exit
(Tare)
Force 0 lbs
Factor:
0.003391 lbs/ADC
Clear


35
5.2.6 Edit Position Factor
In the Edit Position Factor screen the force factor can be changed manually. The
following screen will be displayed.
Exit
(Tare)
Force 0 mm
Factor:
0.003391 mm/ADC
Zero
Tare/
Absol.

Editing the Position Factor.
Press the Enter button to edit the position factor. The following screen will
appear. Use the numeric key pad to edit the value.
Exit
(Tare)
Force 0 mm
Factor:
0.003391 mm/ADC
Clear


36
* Setup Menu *
Exit Select
Change Password
Date and Time
Language
Serial Baud Rate
5.3 Setup Screen
In the Setup Screen, the Password, Date and time and Language can be
changed.

Button Function
option.
SELECT Selects the option the
arrow is
pointing to.
EXIT Returns the software to the
Service Menu.


37
5.3.1 Changing Password
In the Change Password screen, the password can be changed from the default
setting.
* Password Protect *
Exit
Enter Password:
123
Then Press "Enter".
Clear

The system will then prompt you to enter the new password.
* New Password *
Exit
Enter New Password:
123
Then Press "Enter".
Clear

Type in the new 3 digit password and press ENTER. A message will be
displayed
Password Changed.
Press Ok to exit.


38
* Date and Time *
Exit Clear
11 / 19 99
18 : 38 : 1
18 /
* Serial Baud Rate *
Exit Next
Baud Rate: 9600
5.3.2 Changing Date and Time
In the Date and Time Screen, the date and time that is on the RAM chip can be
changed. Press the Edit button to access the edit screen.

Button Function
option.
Clear Clears the selected
number.
Exit Returns the software to the
Service Menu.

Move the edit box to the value to be changed and press the Clear button to clear
the value. Next enter the new value. Press Exit to exit the edit screen and press
Exit a second time to go back to the Diagnostics Screen. Note: To change the
year from 2000 back to 1900s, enter in 99 in the last two digits for the year.
5.3.3 Serial Baud Rate
The Serial Baud Rate screen lets you change the Baud Rate for serial
communication.

Button Functions
Changes the setting inside
the edit box.
Next Not Used.
Exit Returns the software to the
Setup Menu.


39
* Language *
Exit Next
Language: English
5.3.4 Changing Language
In the Language Screen, the Language for the text can be set for English or
German.

Button Functions
Toggles the language from
English to German.
Toggle Toggles the state of the
relay.
Menu Returns the software to the
Setup Menu.


40
6. RS232 Serial Communication
Using the RS232 port, various data from the process can be obtained from the
monitoring system in an ASCII format. The data includes the force and position curve
data (actual and taught), the peak force inside and outside the monitoring window, the
full depth measurements and the touch point data.
6.1 Communication Settings

Baud Rate: 9600, 19200 or 38,400
Data Bits: 8
Stop Bits: 1
Parity: None

6.2 Signal Description

TxD: Transmit signal Data output
RxD: Receive signal Data input

External Connector: 9 pin dSub connector

1 1
2
3
4
5
2
3
4
5
PPM
Machine
Control
Promess
Meter


41
6.3 Command Format

The Monitoring System looks for a string of three consecutive characters followed
by a carriage return. The three characters must be capitalized, otherwise they
are ignored. The request for information must be when the Monitored input is
low.

Every command must be terminated by a carriage return <CR>.

<CR> ASCII<#013>

Line Feed <LF> after a carriage return <CR> will be ignored.

Command Description Availability
PSO Part summary with out slices Later
PSW Part summary with slices Later
TPA Touch point actual
TPT Touch point taught
TPL Touch point limits
TPS Touch point summary
FDA Full depth actual
FDT Full depth taught
FDL Full depth limits
FDS Full depth summary
PFW Peak force window
PFG Peak force global
CWA Curve window actual
CWT Curve window taught
CWL Curve window limits
CWS Curve summary
VAC Value at cursor Later


42
Command: TPT<CR>

Description: Touch Point Taught Value the taught in touch point location is sent
followed by a carriage return.

Data Format: touch point taught value<CR>

Example: 8.23<CR>
Command: TPL<CR>

Description: Touch Point Limits The lower and upper touch point limits are sent out

Data Format:

touch point lower limit x-axis value, touch point upper limit x-axis value<CR>

Example: 8.03,8.43<CR>
Command: TPS<CR>

Description: Touch Point Summary The touch point actual value is sent out followed
by the lower and upper touch point limits and a carriage return.

Data Format:

touch point actual value, lower touch point limit, upper touch point limit<CR>

Example: 8.23,8.03,8.43<CR>
Command: TPA<CR>

Description: Touch Point Actual The touch point location is sent followed by a
carriage return.

Data Format: touch point x-axis value<CR>

Example: 8.23<CR>


43
Command: FDA<CR>

Description: Full Depth Actual The full depth location is sent followed by a carriage
return.

Data Format: full depth location<CR>

Example: 23.74<CR>
Command: FDT<CR>

Description: Full Depth Taught Value The taught in full depth location is sent followed
by a carriage return.

Data Format: full depth taught value<CR>

Example: 23.69<CR>
Command: FDL<CR>

Description: Full Depth Limits The lower and upper full depth limits are sent out

Data Format:

full depth lower limit x-axis value, full depth upper limit x-axis value<CR>

Example: 23.19,24.19<CR>
Command: FDS<CR>

Description: Full Depth Summary The full depth actual value is sent out followed by
the lower and upper full depth limits and a carriage return.

Data Format:

full depth actual value, lower full depth limit, upper touch point limit<CR>

Example: 23.74,23.19,24.19<CR>


44
Command: PFW<CR>

Description: Peak Force Window The peak force value within the monitoring window
is sent followed by a carriage return.

Data Format: peak force window value<CR>

Example; 2343<CR>
Command: PFG<CR>

Description: Peak Force Global The global peak force value is sent followed by a
carriage return.

Data Format: peak force global value<CR>

Example: 2580<CR>


45
Command: CWA<CR>

Description: Curve Window Actual The actual curve within the monitoring window is
sent by sending the x-axis and y-axis values in pairs until all values have
been sent followed by a carriage return.

Data Format:

x-axis 1,y-axis 1,x-axis 2,y-axis 2,x-axis 3,y-axis 3, x-axis n, y-axis n<CR>

Example: 11.00,23,11.10,48,11.20,113, 23.00,1678<CR>
Command: CWT<CR>

Description: Curve Window Taught The taught curve within the monitoring window is
sent by sending the y-axis and x-axis values in pairs until all values have
been sent, followed by a carriage return.

Data Format:

x-axis 1,y-axis 1,x-axis 2,y-axis 2,x-axis 3,y-axis 3, x-axis n, y-axis n<CR>

Example: 11.00,23,11.10,48,11.20,113,23.00,1678<CR>
Command: CWL<CR>

Description: Curve Window Limits - The relative lower and upper limits within the
monitoring window are sent out by sending the x-axis value followed by
the lower limit y-axis value followed by the upper limit y-axis value in triads
until all values have been sent, followed by a carriage return.

Data Format:

x-axis 1,lower limit y-axis 1,upper limit y-axis 1, x-axis 2,lower limit y-axis 2,upper limit
y-axis 2, x-axis n, lower limit y-axis n, upper limit y-axis n<CR>

Example: 11.00,0,123,11.10,0,148,23.00,1578,1778<CR>


46
Command: CWS<CR>

Description: Curve Window Summary The actual curve within the monitoring window
is sent out along with the relative lower and upper limits.

Data Format:

x-axis 1,actual value y-axis 1,lower limit y-axis 1,upper limit y-axis 1,x-axis 2,actual
value y-axis 2,lower limit y-axis 2,upper limit y-axis 2, x-axis n, actual value
y-axis n, lower limit y-axis n, upper limit y-axis n<CR>

Example:

11.00,23,0,123,11.10,48,0,148,23.00,1678,1578,1778<CR>

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